ENGINEERING LETTER

Pump Protection

Excellence in Flow Control

 3

ENGINEERING LETTER
Pump Protection

Introducion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page  5

1.1 Which systems are available to ensure the minimum flow

through the pump at all the times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page  6

1.1.1 Continous bypass system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page  6

1.1.2 Controlled bypass system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page  7

1.1.3 Automatic recirculation valves.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page  8

The automatic recirculation valve application - DETAILS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page  9

2.1 General ARV information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page  9

2.2 ARV installation recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12

2.3 SCHROEDAHL ARV types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14

2.4 The ARV functioning / flow curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15

2.5 ARV operation on pump curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 16

2.6 ARV application with speed operated pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 17

2.7 Engenineering guideline for ARV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 18

2.8 ARV data sheet for communication and RFQ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 19

2.9 Signal exchange of the minimum flow control system.. . . . . . . . . . . . . . . . . . . . . . . Page 19

3.0 Schematic arrangement for control valve solution with venturi nozzle

at pump discharge and signal controlled pump speed.. . . . . . . . . . . . . . . . . . . . . . Page 19

 4

ENGINEERING LETTER
Pump Protection
 5

ENGINEERING LETTER
Pump Protection

Introduction
Because of necessary cost reductions and a higher degree of system efficiency and risk management, a
reliable system that ensures a minimum flow through the pump is an essential requirement, especially for
high pressure applications.
Besides protecting the pump against overheating, a well-engineered, modulating, controlled bypass
system improves the stable operation of the complete system. The system itself is usually a closed loop
application and therefore consists of a suction and recirculation line from the tank and back to the tank.
The materials used for the valves are carefully chosen in order to minimise corrosion and erosion under
high velocity conditions or special medium applications.

Important note
Especially for high pressure applications, all equipment including the valves should fulfil the following
requirements:

Reliable operation
Production stops are very costly. A higher initial investment will pay off in the long run than opting for the
most inexpensive solution (inexpensive can be very expensive!).

Ease of maintenance, good serviceability

Although highly trained technicians are among the platform personnel, the equipment should be main-
tenance-free or require little maintenance by the platform engineers. Time is scarce and costs money
especially on platforms.

Long life of the valve and its trim parts

In order to prevent production loss or unnecessary doubling of control systems. Again, a cost factor!
 6

ENGINEERING LETTER
Pump Protection

1.1 Which systems are available to ensure the minimum flow

through the pump at all times?
1.1.1 Continuous Bypass System
These systems continuously bypass the flow injected causes a tremendous loss of energy.
that is required as a minimum to prevent over- Therefore, the pump to be selected should be
heating of the high pressure injection pumps. larger in size as well as the installed capacity of the
Minimum flow is usually approx. 30% of the driver (130%).
normal flow. The pressure at which the water is

Tank

Also, a pressure reduction system has to be 150-200 m3/h). At a pump head of 2150 m the
provided with orifice plates that are subject to ca- extra power consumption of the larger pumps
vitation and wear. would be 950 kW per hour.
An additional check valve is needed! In continuous operation (say 300 days per year)
Pay attention to saving costs for high pressure and energy costs of 3 cents per kW/h, the extra
applications! energy costs would be roughly $200,000.
In a typical high pressure injection system with a This system is therefore very costly and it is bad
normal flow of 625 m3/h (per pump), the bypass engineering practice.
flow required is a minimum of 125 m3/h (usually
 7

ENGINEERING LETTER
Pump Protection

1.1.2 Controlled Bypass System

This system consists of:

A control valve in the bypass. This control valve the make) is required, and it should be equipped
should be designed for high pressure reduc- with an actuator to provide modulating control. It
tion (e. g. from 200 bar down to 5 bar or lower). should also be available in the materials as
Usually, a four-stage trim (or more, depending on required.

Tank

A flow sensor in the suction line, which senses the The check valve is located on the pump outlet
low flow conditions to the pump. Also available in to prevent back flow if the pump is not running.
a material as specified. Again, the availability of the correct material for this
A control loop which transmits the signal from check valve should be taken into consideraton.
the flow sensor to the control valve actuator. This system has been applied (and still is) in many
This requires an air or electrical supply system and high pressure systems. It offers a good control
requires regular maintenance and calibration. of the bypass flow but has some drawbacks
when compared to the system of an Automatic
An additional check valve is needed!
Recirculation Valve.
 8

ENGINEERING LETTER
Pump Protection

1.1.3 Automatic Recirculation Valves

The Automatic Recirculation Valve, manufactured years, combines the 4 functions as outlined earlier
and marketed by SCHROEDAHL for almost 50 in one simple unit (see below).

Tank

The SCHROEDAHL ARV features:

1. Flow sensing and modulating function
2. Check valve
3. Automatic bypass end connection
4. Pressure reduction of the bypass flow without cavitation

This results in the following advantages compared Conclusion:

to conventional systems: The SCHROEDAHL valves are the most reliable
One self-operated unit only, which can be moun- valves providing minimum flow through a pump.
ted directly on the pump outlet. No external ener­ They have many advantages over other systems
gy required. Reliable, direct operation with little and are low in initial cost (approx. 70% of a
hysteresis. No special maintenance required; the conventional system). The valves are based on
unit is self-lubricating (pump fluid). the latest technology, and SCHROEDAHL has
nearly 50 years of experience since the valve was
invented by Mr. Odendahl of SCHROEDAHL.
 9

SCHROEDAHL Pump Protection

Engineering Letter

The Automatic Recirculation Valve Application – DETAILS

2.1 General ARV Information

Q
P2

Suction
tank

QA Qmin

PA PN
Q P

Bypass

PV
Manual-start-up*
P1
Pump

*Manual-start-up on request/optional

Explanation
and a special control device for the minimum flow
The Automatic Recirculation Valve (ARV) pro-
recirculation (the bypass control system). The
tects centrifugal pumps against overheating and
general valve functioning is related to the process
cavitation problems by automatically maintaining a
flow quantity – all SCHROEDAHL ARVs are flow
minimum flow when the system flow is in low load
sensitive.
condition. The application itself is usually a closed
loop application and consists of a suction and Simplified function explanation: An increasing
recirculation line from the tank and back to the process flow will automatically reduce the bypass
tank. Typically the ARV is directly mounted on the flow. At a certain level of process flow (the valve
pump discharge flange. switch point), the recirculating bypass is closed.

The valve system comprises a high quality check

valve in the main line (see symbol above right)
 10

ENGINEERING LETTER
Pump Protection

2.1 General ARV Information

ARV-Valve Function Description and Options

The ARV comprises a high quality check valve
in the main line and a special modula­ ting
control device for the minimum flow recir-
culation (bypass system). The general valve
function­ing is related to the process flow quan-
tity – all SCHROEDAHL ARVs are flow sensitive.

Definitions:
Q100 - (m3/h, US GPM) Rated process flow (for ARV valve design)
QM - (m3/h, US GPM) Pump minimum flow (for ARV bypass design)
HM - (m, feed) Pump differential pressure at minimum flow
Pv - (bar g, psi g) Pump suction pressure
Pn - (bar g, psi g) Bypass back pressure (at bypass flange of ARV)

Pump pressure H vs. Q (in %)

180 %
B) Special application
160 %

140 % Rated point

P100
120 % (Q100; H100)

100 %
Pump head (in %)

Minimum flow
point Valve bypass
80 % PM (QM; HM) switch point SP

60 %

40 %

20 %
A) Special application
0%
0% 20 % 40 % 60 % 80 % 10 % 120 % 140 %

Pump flow (in %)

H (%) Design points Valve switch point

 11

ENGINEERING LETTER
Pump Protection

Normal or Special Operation Range Definition and Bypass Back Pressure

The pump operation data is the basic design data flow point and the rated process flow point.
for the automatic pump protection valve and has Please note: At the minimum flow point, the
therefore an influence on the valve design. The re- ARV bypass is completely open, and at the rated
lation between the normal rated flow and the pump point, the full pump flow is going to the system.
minimum flow is also important. Normally the pump An optimal valve design can only be achieved
minimum flow is not more than 30% of rated flow. when the operation data are complete. There­
The following pump curve example should ex- fore the pump protection has to be split into
plain the ARV functioning with the minimum NORMAL and SPECIAL.

A) Normal Application is defined when the process Special: The Special Application (B) (> 120 bar
flow is typically not below 40% of the rated flow / > 1740 psi) needs information about the static
(beside short start-up phases). and dynamic bypass back pressure Pn (stat.
B) Special Application is defined when the system / dyn.) as well as a check about the correct
flow range is from 0% to 100% of the range bypass piping system with incorporation of the
specified. If the pump pressure is also greater medium temperature rise at minimum flow.
than 120 bar / 1740 psi, then a Back Pressu- B) High Pressure Applications
re Valve (BPV) is required, as a simple orifice
For applications with ≥ 120 bar / > 1740 psi
cannot ensure that the back pressure Pn will
differential pressure, a Back Pressure Valve
be a minimum of 4 bar / 58 psi higher than the
(BPV) is recommended. The BPV should
saturation pressure (guide value, value range is
be installed directly before the inlet into
4 to 10 bar / 58 to 145 psi).
the tank to keep the pressure in the
recirculation line (Pn) at a minimum of 4 bar
Note:
/ 58 psi higher (rough thermodynamic safety
A) Differentiation between Normal and Special: margin, maximum up to 10 bar / 145 psi
Normal: An application will be classified as possible and confirmed by SCHROEDAHL).
Normal (A), when no operation range informa-
tion is given.

Medium Temperature Rise

Based on thermodynamic rules due to the pressu- mum flow, the temperature rises between 10 °C
re increase and decrease, plus friction losses, the and 20 °C (for HP feed water applications). Please
temperature of the medium rises within the pump take this into consideration for the recirculation
(refer to I. J. Karassik) and ARV bypass system. system up to the inlet of the deaerator / feed water
With typical low efficiency of the pump at mini- tank (flashing and choked flow collapse).
 12

ENGINEERING LETTER
Pump Protection

2.2 ARV Installation Recommendations

To the Place for BPV

system Straight pipe run >
_ 3 x DN or orifice as
near as possible
to the tank

ARV

Tank

Best distance: Zero or

maximum 3 m straight
pipe run of >
_ 2 x DN.
No elbow allowed at inlet.

Note: Vertical installaion of the ARV directly on the pump discharge is best!

Back Pressure Valve Information

If a Back Pressure Valve (BPV) or Anti-flashing size should be preferably 1 size larger – due to
Device is requested, it should be installed as near flashing!
as possible to the tank and the downstream pipe

Installation Conditions
• Vertical installation is preferred, horizontal on •
Downstream of the bypass should be in a
request. straight pipe run of 3 x DN (no elbows).
• Preferred installation is directly on the pump • Standard filter mesh size should be 0.3 to
discharge flange. Otherwise, if possible, no 0.5 mm (pump suction side). For commission­-
farther downstream than about 3 metres after ing we recommend using a smaller mesh size
the pump (depends on the application). (of 0.1 mm).
• The recommended straight pipe run at the inlet •
After commissioning a valve inspection is
should then be at least 2 x DN (no elbows at recommended.
the inlet).
 13

ENGINEERING LETTER
Pump Protection

For 2 x 50% pumps application

Recommended individual bypass line for 2 x 50% pumps.

High Low
pressure pressure
piping piping possible

BPV

Possibility for rating step down.

 14

ENGINEERING LETTER
Pump Protection

2.3 SCHROEDAHL ARV Types

SUL
• Max. class 300 / PN 63
• Cast body
• Economic and efficient design

TDL
• Max. class 900 / PN 160
• Forged body
• Check valve in the bypass
• Venturi ring design

TDM
• Max. class 2500 / PN 400
• Forged body
• High pressure reduction bypas device
(up to 5 stages)
• Non-return function in bypass

MRK
• Max. class 4500 / PN 640
• Forged body
• High pressure reduction bypass
system for pressure reduction
up to 500 bar.
 15

ENGINEERING LETTER
Pump Protection

2.4 The ARV Functioning / Flow Curve

Modulating Bypass Function

All SCHROEDAHL valves have a modulating func- During zero process flow, the bypass is comple­
tion; they do not have a simple ON / OFF function. tely open. The pump is running with the specified
Therefore, with the modulating function, they can minimum flow. When increasing the process flow,
handle load cases between zero process flow and the bypass flow will decrease accordingly.
the minimum pump operating conditions without
loss of energy.

100 1,100 R

90
0,900
80

P
Pressure drop (in bar)

70
P
Main flow (in m3/h)

0,700
60
Switch point
50 SP 0,500

40
Bypass flow
0,300
30

R Pump flow P
20
Bypass 0,100
10
Process flow R
0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Pressure drop
Lift of check valve (in %)

Above flow curve shows the valve behaviour for the flow reduction process (shut-down event).

Example curve with design conditions: 30 % of the rated pump flow, the valve switch point is
about 25 % higher than the specified minimum flow:
Q100% = 100 m3/h
Q min = 30 m3/ h SP ~ Qm x 1,25

Valve switch point (SP) This very low switch point is one of the advantages
For normal operation conditions with TDM-Valves, of SCHROEDAHL valves!
where the bypass flow is not higher than about
 16

ENGINEERING LETTER
Pump Protection

2.5 ARV Operation on Pump Curve

Please refer to the following principal pump curve according to the typical pump curve (pressure
to understand the characteristics of an ARV head over pump flow).

Pump pressure Q vs. H (in %)

180 %
Normal operating range
160%

140% Rated point

P100
120% (Q100; H100)

100%
Pump head (in %)

Minimum flow
point Valve bypass
80% PM (QM; HM) switch point SP

60%

40%

20%

0%
0% 20% 40% 60% 80% 10% 120% 140%

Pump flow (in %)

H (%) Design points Valve switch point

Definition
For the curve, the normal operation point (rated Usually, the system operation is between 40% to
point) is stated as the 100% case with H = 100% 100 % and therefore above the valve switch point
at Q = 100% (see graph above: normal operation).

Explanation Operation Range of Pump Protection

The bypass flow will decrease when the flow HP applications, which should operate from 0% to
to the system (process flow) is increased. 100% process flow, require detailed engineering
Therefore, the bypass flow reduces from the and have to be confirned before order processing
minimum flow point to the switch point. At the ARV (see section 2.1).
switch point, the bypass flow is closed.
 17

ENGINEERING LETTER
Pump Protection

2.6 ARV Application with Speed Operation Pumps

The ARV is flow sensitive Valve calculation

As the ARV functioning is related only to the pro- For the valve design we calculate / incorporate all
cess flow quantity, the valve will not have a pro- given speeds with the valve‘s minimum flow points
blem when it must operate at lower pump speeds and will ensure that all different operation points
/ lower pump pressures. This is a very big advan- are covered (worst case scenario). The ARV pump
tage of the ARV solution compared with a Control protection will have a large and sufficient opera­
Valve system. tional range.
The ARV is able to handle speed-operated pumps –
easily!
Typical Speed Operation Pump Curve

Pump pressure Q vs. H (in m3)

3900
3700
Max. speed curve
3500
3300
3100
2900
2700 Line of minimum
2500 pump flow
Head-metres

2300
Min. speed curve
2100
1900
1700
1500
1300
1100
900
700
500
0 50 100 150 200 250 300 350 400 450 500 550
Flow (in m ) 3

Note: Please also inform us about the load data if a booster pump with constant speed is installed.
 18

ENGINEERING LETTER
Pump Protection

2.7 Engineering Guideline for ARV`s

Materials

• Standard temperature range from -196 °C to +260 °C (LP up to +400 °C)

• Standard sealing material is EPDM, NBR, FKM, FFKM
• SUL valves are available in CS and SS housing material only (cast body)
• TD, MRM and MRK valves: CS, SS, LT, Duplex, Super Duplex
Special materials on request!

Differential Pressure at Rated Flow

• The differential pressure at rated flow (based on normal medium velocities of 4 to 5 m/s):
• SUL approx. 0.3 bar
• TDL approx. 0.4 bar
• TDM approx. 1.0 bar (approximate figures, depending on load conditions)

Installation Conditions

• Preferred vertical, horizontal on request.

• Preferred installation is directly on pump discharge flange, otherwise, if possible, no farther downstream
than about 3 metres after the pump (depends on application).
• Standard filter mesh size should be 0.3 to 0.5 mm (pump suction side). For commissioning
we recommend a smaller filter size of 0.1 mm.

Examinations, Tests and Certificates

• Standard certificates acc. EN 10204 / 3.1 and 97/23/EG (PED for CE marking for Europe).
• Leakage:
Main Check Valve: FCI 70.2 Class IV (all valves)
• Bypass: FCI 70.2 Class IV (only TDM / MRM valves); TDL and SUL are not tight closing (LP application).
• Witnessed inspection by customer or third party inspection.
• Non-destructive examinations on request for TD, MRM and MRK series (not for SUL type).
• Bypass Kv Value test certificate, on request.
• Flow curve for TDM, MRM and MRK series, on request.
 19

ENGINEERING LETTER
Pump Protection

Data Sheet
ARV Data Sheet

Rev. prev. Order No.

Customer Data Sheet No.
Quantity
Project
Tag No. / KKS No.
Type

Valve Design
Connection Size Class Standard Schedule Surface
P Inlet
R Outlet
B Bypass
A Start-Up
Installation P-R
Painting
Certificates

Design Data
Design Temp. Design Pressure

Material
Body Internals Gaskets

Medium
Medium
Operating Temp. min. max.
S.G. min. max.

Operating Data
Case 1 Case 2 Case 3
QM
HM
Q100
H100
Qmax
Hmax
H0
QA
HA
pv
pN
DpBypass
kv-Bypass
RPM

Remarks

Revision Date Description Name

SCHROEDAHL
SCHROEDAHL GmbH GmbH
AlteSchönenbacher
Alte Schönenbacher
Str. 4 · 51580Straße 4 | 51580
Reichshof-Mittelagger Reichshof-Mittelagger
Telefon +49 2265 9927-0 · Telefax +49 2265 9927-927
circor.com
eMail: | www.schroedahl.com
schroedahl@circor.com · www.schroedahl.com Version 1.07 / 20.03.2019

Minimum requirement to create an offer

 20

ENGINEERING LETTER
Pump Protection

SCHROEDAHL GmbH
Alte Schönenbacher Straße 4
51580 Reichshof-Mittelagger
Telephone + 49 22 65 99 27 - 0
Fax + 49 22 65 99 27 - 927
www.schroedahl.com
schroedahl@circor.com